Methods of and apparatus for separating solid and liquid particles from air and other gases

ABSTRACT

Processes and systems for separating solid and/or liquid particles from air or other gases in which the gas is caused to move with the particles dispersed in it to the highest intensity region of a non-uniform electrical field where the particles are collected.

United States Patent [191 Gothard June 25, 1974 1 1 METHODS OF AND APPARATUS FOR SEPARATING SOLID AND LIQUID PARTICLES FROM AIR AND OTHER GASES Inventor:

[76] Nicholas Gothard, c/o Filteron International, lnc., 2322 Irving Blvd., Dallas, Tex. 75207 Filed: Dec. 15,1972

Appl. No.: 315,416

Related US. Application Data Division of Ser. No. 159,690, July 6, 1971, which is a continuation-in-part of Ser. No. 793,224, Jan, 13, 1969, which is a continuation of Ser. No. 629,465, April 10, 1967.

US. Cl. 55/13 Int. Cl. B03c 3/06 Field of Search 55/2, 101, 103, 130, 139, 55/146, 150, 154, 155, DlG.38, 135,5, 6, 10,l3,112,113,118,120,123,129,131,

136, 141; 310/2, 6; 317/262 R; 204/188, 299, 300, 301, 302, 303, 304, 180 R, 186; 250/527, 531; 209/127 R; 23/288 R, 288 F [56] References Cited UNITED STATES PATENTS 3,129,157 4/1964 Loeckenhoff 204/180 3,304,251 2/1967 Walker et a1. 204/184 3,431,441 3/1969 Shair 55/151 X Primary Examiner-Dennis E. Talbert, Jr. Attorney, Agent, or Firm-Strauch, Nolan, Neale, Nies & Kurz [57] ABSTRACT Processes and systems for separating solid and/or liquid particles from air or other gases in which the gas is caused to move with the particles dispersed in it to the highest intensity region of a non-uniform electrical field where the particles are collected.

.lZQa ma filsDsawinsi i a Gas "*'ci rculator tit-III! a. lludm w."

- Power 53 pp y sum in or 12 Inner conductor 7 PRIOR ART Typical stationary at high voltage gas molecules Grounded outer conductor- Non uniform field region Dust particle Inner conductor T cal as 1 st at high voltage P 9 C U r moving, along with the particles Grounded outer conductor Non uniform field region Dust particle FIG 2 Gas ci rculator I Pmmwmz mu saw 020F12- PAIENIEMuuzsmn saw our 1 PAIENTEDJ NZ 3,818,678 sam os nr12 mum-25w 3.818.678

sum 09 HF '12 v U 2 E U E m ELECTROSTATIC w PRECIPITATION 5 H5 FIG 25 TIME IN. HOURS CORONA ONSET VOLTAGE IN KILOVOLTS IN AIR l0' l0 no" 1 CENTRAL ELECTRODE RADIUS "0" IN METERS FIG 29 Pmmmmaslm 3,818,678

sum 10nr12 METHODS OF AND APPARATUS FOR SEPARATING SOLID AND LIQUID PARTICLES FROM AIR AND OTHER GASES RELATION TO THE OTHER APPLICATIONS This is a division, of application Ser. No. 159,690, filed July 6, 1971 which is a continuation-in-part of application Ser. No. 793,224 filed Jan. 13, 1969. Application Ser. No. 793,224 is a continuation of application Ser. No. 629,465 filed April 10, 1967.

The present invention relates to gas separation methods and apparatus and, more specifically, to methods and apparatus for separating solid and liquid particles in-which air and/or other gases having the particles dispersed therein are passed through nonuniform electrical fields and, at the same time, exposed to a current which is not large enough to charge the particles but is large enough to cause limited ionization of the gas. The object of the separation may be either the purification of the gas or the recovery of the solid or liquid.

A wide variety of techniques for separating particulate materials from air and other gases have heretofore been proposed. Among these are inertial or cyclone separators, scrubbers, filters, and electrostatic precipitators.

Inertial separators are widely used, but have the drawback that they do not remove small particles because the latter tend to be essentially inertialess.

Scrubbers, of which there are several types, are also extensively used. However, scrubbers are, as a rule, expensive to manufacture and install. They also tend to be expensive to operate because of high power requirements and because they employ parts which have a short service life.

A variety of filter type separators have also been developed for different purposes. Again, however, such devices have their limitations. For example, cleaning often presents a problem. Also, for the most part, filters are not practical where liquid or hygroscopic particles are to be removed. Further, such devices are impractical for applications involving high flow rates.

Electrostatic precipitators are used extensively because they have a high collection efficiency for all but small particles and are useful where large volumes of gas are to be cleaned. In this type of separation device,

the gas to be cleaned flows between two oppositely charged electrodes across which a high enough electrical potential to produce a corona discharge is maintained. As the particles move through the corona discharge, they are charged and attracted to the electrode having the opposite polarity. 1

"Such devices may also be of the two-stage type in which the particles are charged by a corona discharge field in a first stage and then separated in a second stage by passing the gas in which they are dispersed between charged electrodes.

While useful for many purposes, this type of device is by no means without drawbacks. For example, electrostatic precipitators cannot be employed to separate particles having high conductivity. On the other hand, particles having extremely low conductivity will coat out on and insulate the electrode to which they are attracted and thereby cause a decrease in efficiency. Also, such devices are expensive; the employment of corona producing elements such as thin wires makes them very fragile mechanically; and precleaners may be required where large particles are present.

Another and important disadvantage of this type of device is that relatively large amounts of ozone are produced by the corona discharge. Ozone is deadly in even small concentrations; and electrostatic precipitators can accordingly not be employed in closed areas.

U.S. Pat. Nos. 3,110,580 issued Nov. 12, 1963, for DEVICE FOR AGGLOMERATING MICROSCOPIC PARTICLES and 3,304,251 issued Feb. 14, 1967, for SEPARATION OF WAX FROM AN OIL DISPER- SION USING A NONUNIFORM ELECTRICAL FIELD; published Japanese Pat. Publication No. 293,153 dated Nov. 25, 1950, for ELECTRICAL DUST-CATCHING EQUIPMENT; and German Pat. No. 571,159 dated Feb. 24, 1933, for VERFAHREN ZUR ABSCHEIDUNG VON SCHWEBEKORPEN AUS GASEN MITTEL EINES SPRUHENTAL- LADUNGSFRIEN ELEKTRISCHEN FELDS, suggest that yet another electrical phenomenon, a non-uniform electrical field, can be employed to separate particles from gases although none of these patent publications contains any concrete information as to how a nonuniform field can be employed for this purpose; i.e.,

they do not disclose any of the parameters or relationships among parameters which must be observed in order to separate particles from gases by using a nonuniform field.

Accordingly, it must necessarily be assumed that the devices proposed in these patents were intended to operate in a manner in which they would be expected to produce the highest efficiency as predicted by the accepted theory governing the motion of particles in nonuniform fields. At the time the applications maturing into the foregoing publications were filed and at the present time as well, the theory in question states that, if an uncharged dielectric particle is placed in a nonuniform electrical field inwhich there is essentially no current flow, a net force attributable to the spatial nonuniformity of the field will drive the particle toward the region of the field in which the field intensity is the highest at a velocity proportional to the size of the particle. Practice confirms this theory; fields as heretofore disclosed are efficient where the particles to be collected are of relatively large (e.g., micron) size. However, as the particle size decreases, collection efficiencies of the heretofore proposed separation devices employing non-uniform fields decrease markedly. Consequently, such devices are not practical for applications where small particles (in the sub to 10 micron range, for example) are involved.

See, for example, Polar Molecules, by Peter Debye. The Chemical Catalog Company, Leipzig (1929);

Herbert A. Pohl, The Motion and Precipitation of Suspensoids in Divergent Electric Fields," J. Appl. Phys, 22,869 (1951);

H. F. Kraemer, Properties of Electrically Charged Aerosols," Technical Report No. 12, Engr. Experiment Station, Univ. of Illinois, Mar. 31, 1954;

L. Silverrnan et al., Electrostatic Mechanism in Aerosol Filtration by Mechanically Charged Fabric Media and Related Studies, USAEC REPORT NYC-4610. Sept. 4, 1956;

Herbert A. Pohl, Some Effects of Nonuniform Fields on Dielectrics," J. Appl. Phys., 29, 1182 (1958);

H. A. Pohl and J. P. Schwar, Factors Affecting Separations in Nonuniform Electric Fields, J. Appl. Phys., 30, 69 (I959);

H. A. Pohl and J. P. Schwar, "Particle Separations by Non-uniform Electric Fields in Liquid Dielectrics. Batch Methods," J. Electrochemical Society, 107, 386 (1960);

H. A. Pohl and C. E. Plymale, "Continuous Separations of Suspensions by Nonuniform Electric Fields in Liquid Dielectrics," J. Electrochemical Society, 107, 390 (1960);

Herbert A. Pohl, Nonuniform Electric Fields," Scientific American, 103, 107 (1960);

R. B. McEven,"Method and Apparatus for Dielectrophoretic Separation of Polar Particles" U.S. Pat. No. 3,197,393, Mar. 27, l96l;

V. C. P. Morfopoulos, Use of Inhomogeneous Electrical Fields in Processes Influenced by Electrical Fields, US. Pat. No. 3,447,049, May 5, 1965; and

V. C. P. Morfopoulos and N. Arbiter, Contribution to the Science of Electrostatic Separation-Dielectric Forces in Inhomogeneous Fields, Soc. of Mining Engineers, 352, Dec. (I965).

I have now invented a novel process and apparatus for separating solid and liquid particles from air and other gases which resembles that just described to the extent that a non-uniform field is employed. However, my method and apparatus operate in a completely different manner and have a quite different capability in that they collect particles of even submicron size in very short periods (on the order of seconds) with efficiencies approaching 100 percent.

In one important respect my novel technique of separating particles from air and other gases differs from that just described in that I deliberately produce a small current flow from one to the other of the two conductors between which the non-uniform field is established. As will be explained in detail later, this current ionizes a small number of the gas molecules flowing through the non-unifonn field. These molecules act as sites about which uncharged particles tend to cluster and form what I term an ensemble of gas molecules. These ensembles therefore constitute aggregations of molecules which can be acted on collectively by the force created by the non-uniform electrical field and moved toward the high intensity region of the nonuniform field. The force is accordingly appreciably greater than that which can be exerted on a single gas molecules and substantial velocities can be imparted to the ensembles. At the same time, I keep the ionizing current sufficiently low that the particles of material being separated are not charged to the point where they will move by electrophoresis.

"'This deliberate provision of a small current readily distinguishes my invention from the technique described in the above-cited German Pat. No. 57 l,l59 in which it is stated that there should be no current flow.

It will be obvious to those conversant with the relevant arts that these ensembles do not exist as discrete, physically isolatable entities. Rather. they are best-thought of in terms of the electrical charge distri bution in the gas flowing through the non-uniform field.

Because of the movement of the gas toward the high intensity region of the non-uniform field, the movement of the dispersed particles relative to the gas is materially lower than in the previous separation devices employing non-uniform electrical fields. Therefore, the drag forces on the particles are much lower (in some cases so small as to be non-existent for all practical purposes). Consequently, the very small forces available to move particles of small size are nevertheless much larger than the opposing drag forces; and even these small particles move to the high intensity region of the non-uniform field with velocities which give collection times as low as a few seconds. Also, because of the reduction in drag forces, collection times are shorter and efficiencies higher, even where larger particles are involved.

From the foregoing it will be apparent that my novel technique has a combination of advantages which is not even remotely approached by the devices heretofore available for separating particles from air and other gases. Specifically, it can be used to separate particles which are too small to be removed by many heretofore available methods including those employing nonuniform fields. Also, separation devices according to the present invention have extremely high efficiencies, even in applications involving extremely small particles or a wide range of particle sizes.

In addition, particle separation or removal devices in accord with the present invention are simple and have extremely low power requirements. They are accordingly relatively inexpensive to manufacture and install and to operate and maintain.

Yet another advantage of the instant invention is that, in contrast to electrostatic devices, there is no generation of ozone. Therefore, apparatus in accord with my invention can be employed in closed, inhabited areas and in other applications where the electrostatic devices cannot be used because of the high mammalian toxicity of ozone.

Yet another advantage of the present invention is that it can be employed to remove liquid and hygroscopic as well as non-hygroscopic solid particles. Also, devices employing its principles are capable of handling large volumes of gas; and high flow rates can be readily accommodated. Furthermore, collected particles can be readily removed from the separation devices by any of a variety of techniques.

Still another advantage of my invention is that pressurization of the gases from which particles are to be separated is not required. Consequently, separation by the techniques I have invented can and normally will be a continuous type process in contrast to the batch-type techniques such as described in the above-cited German Pat. No. 571,159.

Another advantage of my invention, not possessed by separators of the charged particle type, is that accumulation of collected particles on a collecting electrode poses no problems inasmuch as this causes no decrease in efficiency. In fact, as will be discussed in detail later, a buildup of collected particles can be employed to increase operating efficiencies in certain applications of the invention.

A further advantage of my invention is that devices in accord with its principles are capable of operating efficiently under variable operating conditions. Still another highly important advantage of my invention is its versatility. The following are merely exemplary of the uses to which it may be put on an economically practical basis:

Removal of the pollutants from the intakes and exhausts of internal and external combustion engines Vapor and fluid particle reduction to liquid phase in desalinization, stream generation, heat exchange, and other processes Elimination of pollutants from gases generated by incineration and burning Petrochemical industry waste reduction and condensation Intake and exhaust and on location dust and pollution elimination from industrial plants Mining and crushing intake and exhaust gas cleaning Cleaning of air for living and working spaces, air intake helmets, and the like.

One important and primary object of the present invention resides in the provision of novel, improved methods of and apparatus for separating particulate solids and liquids from air and other gases. Other related and important but more specific objects of the present invention reside in the provision of methods and apparatus in accord with the preceding object:

l which have high operating efficiencies, even where very small particles or a wide distribution of particle sizes are involved.

2. which, in conjunction with the preceding object,

employ a non-uniform electrical field, but are capable of separating smaller particles than can be separated by devices employing non-uniform fields v as heretofore proposed in periods of reasonable du-' rations.

3. in which, in conjunction with the preceding object, there is a low magnitude current (so low that it is not capable of charging the particles) between the field establishing conductors or electrodes which results in reduced drag forces on the particles being collected so that even the weak forces available to act on very small particles will move the latter to the region in which they are collected at velocities producing very short collection times.

4. which are relatively inexpensive to manufacture, install, and operate and which have a long service I life.

5. which do not generate appreciable quantities of ozone during operation and can accordingly be used in applications where the presence of ozone cannot be tolerated.

6.which can handle large volumes of gases and which are capable of accommodating high flow rates.

7. which are capable of maintaining high collection efficiencies despite the accumulation of collected particles.

8. which are capable of operating efficiently under variable operating conditions.

9. which are highly versatile.

10. which, in conjunction with the preceding object,

can be employed in applications where purification, decontamination, or reduction in the liquid content of a gas is the goal, and applications where recovery of a substance or substances mixed with the gas is the goal as well as in the removal of solid particles from gases.

1 1. that employ devices from which collected particles can readily be removed.

12. which have various combinations of the foregoing attributes.

. Other important objects and novel features and additional advantages of the present invention will become apparent from the appended claims and as the ensuing detailed description and discussion of the invention proceeds in conjunction with the accompanying drawing, in which:

FIG. 1 is a diagrammatic representation of a device for separating particles from gases which employs a non-uniform field in accord with currently taught precepts;

FIG. 2 is a similar representation of a device having comparable geometry for separating particles from gases in accord with the principles of the present invention;

FIG. 3 is a view of one form of apparatus for separating solid .and liquid particles from air and other gases in accord with the principles of the present invention, the separation unit of the apparatus being shown in sec tion;

FIG. 4 is a side view of a second form of separation unit embodying the principles of the invention, part of the external housing of the unit being broken away to show its internal construction;

FIG. 5 is a pictorial view of a stack equipped with apparatus for separating particulate solids from gases flowing therethrough in accord with the principles of the present invention;

FIG. 6 is a pictorial and partially exploded view of apparatus in accord with the present invention which is intended 9 for removing particles from gases on a large volume scale;

FIG. 7 is a vertical section through one of a plurality of integral separation units incorporated in the apparatus of FIG. 6;

FIG. 8 is a pictorial view of a spherical electrode separation unit constructed in accord with the principles of the present invention;

FIG. 9 is an exploded view of a multi-cellular type separation unit embodying the principles of the present invention;

FIG. 10 is a pictorial view of a separation unit in accord with the principles of the present invention which employs grid-type electrodes, part of the external casing of the unit being broken away to show its internal components;

FIG. 11 is a view similar to FIG. 10 of an embodiment of the invention which employs wavy plate electrodes;

FIGS. 12-16 are sections through separation units in accord with the present invention having still different electrode configurations;

FIG. 17 is a generally diagrammatic section through apparatus in accord with the present invention showing how separation units as disclosed herein can be connected in series;

FIG. 18 is a pictorial, generally diagrammatic view of a separation unit in accord with the present invention equipped with a cleaning device for removing from the separation unit material collected by it;

FIGS. 1924 are views similar to F IG. 18 showing alternate forms of cleaning devices;

FIG. 25 is a graph in which the performance of apparatus in accord with the principles of the present invention is compared to the performance of an electrostatic precipitator;

FIG. 26 is a pictorial view of a device in accord with the principles of the present invention in which a nonuniform field having its high intensity region between cooperating electrodes is generated;

FIG. 27 is a partial longitudinal section through the device of FIG. 26;

FIG. 28 is a partial vertical section through a device in accord with the principles of the invention which is designed for collecting liquids;

FIG. 29 is a plot of inner electrode diameter versus corona onset voltage for a device in accord with the principles of the present invention having the electrode configuration shown in FIG. 2; and

FIGS. 30a and 30b show mathematical relationships for certain exemplary embodiments of the invention.

In the process of separating solid and liquid particles from gases which I have invented, the gas in which the particles to be separated are dispersed is caused to flow through a non-uniform, high-density electrical field established by creating a high potential between cooperating, electrically isolated conductors. As the gas traverses the electrical field, the field exerts a force on the particles mixed with the gas, deflecting or moving these particles to the region of the field where the field intensity or strength is the highest. Here the particles can be trapped or collected. The gas, then essentially free of particulate material, can be removed from the apparatus through a suitable outlet or offtake. It will be shown later that this process can be practiced in devices of widely varying configuration.

As discussed briefly above, the basic mechanism of this novel technique I have invented for separating particles from gases differs markedly from the prior art" technique of employing non-uniform fields. More specifically, the motion of particulate matter in a fluid under the influence of a non-uniform field as established in heretofore proposed devices employing such fields depends on a force balance given by the equatron:

F =F +F where F and F I are the non-uniform electrical and inertial forces on a single particle in the field, and F is the drag force on the particle as it moves through the fluid. The electrical force, F depends on the voltage applied to the conductors between which the nonuniform field is established. The drag force, F depends on the particle radius, the particle velocity relative to the fluid and the viscosity of the fluid through which the particle moves.

In the prior art systems the viscous drag force F D is much larger than the inertial force F I for times of interest for practical fluid cleaning systems because they operate by propelling the particles being separated through a fluid medium of appreciable viscosity which is stationary or moving in a different direction than the particles. In this case:

In terms of the physical variables pertaining to the prior art devices, Equation (2) takes the form:

The solution for the radial velocity for a particle of radius R in a prior art device of the configuation illustrated in FIG. 1 is given by the formula:

where p. is the absolute viscosity of the fluid in the annulus, V is the applied voltage at r=a, s, is the permittivity of the fluid, and K is the relative dielectric constant of the particle with respect to the fluid. An average radial drift time T, i.e., the time required for a particle to move from r= b to r =a, may also be calculated from Equation (3) by a simple integration. This equation is as follows:

T 31L (b a) (K+ 2) (ln[b/a]) /8e, R (K l) V From the geometric constants of a separator and Equation (3) a formula for the efficiency of a device of the type in question can be calculated. This formula is:

where A is the surface area of the collecting region, Q is the volumetric flow rate, and v is the average drift velocity of the pollutant particles to the collecting region as given by Equation (3).

The following table gives collection times and efficiencies for a typical device operating in accord with the foregoing Equations:

" That "prior art" hardware performs in accord with the analytical predictions of Equations (3), (4), and (5) is apparent from US. Pat. No. 3,304,251.

lection times become impossibly long and efflciencies impractically low as particle sizes decrease significantly below microns.

Many, if not most, separation problems involve the collection of particles in the sub-micron range as well as larger particles which are nevertheless well below the size which the prior art devices can collect with useful efflciencies in suitably short collection times. Accordingly, as far as the separation of particles from gases is concerned, such devices have remained laboratory curiosities.

In contrast to that just described, the novel separation process I have invented provides high collection efflciencies and extremely short collection times, even when the particles being collected are of sub-micron size.

In my novel process, viscous drag forces on the particles being separated are substantially reduced (or even made so small as to be essentially non-existent) by causing the gas in which the particles are dispersed to move with the particles to the maximum intensity region of the non-uniform field. As gases have relative dielectric constants approaching unity, this requires that the gas be polarized so that the gas atoms will move collectively in an ensemble to the maximum field intensity region. That is, the forces due to the field which is available to act on a single, polarized, non-interacting atom or molecule as postulated in the theories currently in vogue are not sufficiently large to produce the desired flow of the gas to the maximum intensity field region. However, I have found that the requisite collective motion of the gas can be obtained by creating a small current between the conductors across which the non-unifonn field is established. It is believed that this small current produces a slight degree of ionization in the gas and that neutral gas molecules are attracted to the ionized molecules, thereby forming molecular clusters which are large enough to be subjected to substan- 9 tial polarization forces (it appears that the theoretical cluster size must be at least 10 to 20 molecular diameters for the gas to move with the particulate).

AS in the case of the prior art devices, the operation In situations where the electric field is inversely proportional to the radial distance leading to the origin of the coordinate, system Equation (6) takes the form:

d rldt (Q/p) 1/;

where Q is a proportionality constant dependent on voltage and the dimensions of the structure, e.g.:

for coaxial structures as shown in FIG. 2. The solutions to Equation (7) subject to the boundary condition at t= 0, r r and V dr/dt 0 are:

r 1 [mp/s 1: we o/p) we Also, with reference to FIG. 2, it is possible to calculate the average drift velocity for the present invention from the last equation. This drift velocity equation is as follows:

where v, is as defined in Equation (7) and v is the observed drift velocity of the particles under specific operating conditions. However, it does not appear that slip is a limiting factor because of the close correlation between observed results and calculated results in which slip is disregarded.

The equation for efficiency applicable to my invention is also However. v" in Equation (5) is calculated by Equation (7) above. rather than Equation (3) as in the case of those heretofore proposed separation devices employing non-uniform fields.

Calculated efficiencies and collection times agree closely with actual test results as shown by the data for the operation of a typical embodiment of my invention tabulated below:

TABLE II a l.75 in Length 48 in. b 5.0 in. Volumetric Flowrate 28.5 c.f.m. V I00 kV Particle Size 0.3g. (highly uniform) Calculated Observed Collection Time L sec. 1.56 sec. Efficiency 90.6% 93% Also, as can be readily seen from a comparison of the data in Tables I and II, the devices of the present invention are much more efficient separators of small particles than those predictable from the theories governing the effects of non-uniform fields.

It is important, in operating devices of the type I have invented, that the current flowing between the electrodes be carefully regulated. Specifically, the maximum current density must be kept in the range of 10 to 10 ampere per square centimeter. At higher current densities, unwanted corona discharge will occur; and the system will operate as an electrostatic precipitator instead of in the desired manner. At current densities below the minimum specified above, the gas will not be ionized to the extent necessary to produce the collective polarization of the gas required for flow of the gas to the maximum field intensity region of the non-uniforrn field.

In regard to the preceeding paragraph, the force available to move the gas to the high intensity region of the non-uniform field is proportional to the dielectric constant K of the gas traversing the non-uniform electrical fields and the dielectric constant is in turn proportional to the theoretical cluster size as shown by the following equation;

K= (1 C R )/(l C R TABLE III Cluster Radius Composite Fluid in Meters Dielectric Constant I01: l.0005 3 X [0 l.0080 6 X l0 l.0660 9 X l0 l.2360 1.5 X l0' 2.5300

l. Close to the ucccptcd of room air.

In conjunction with the foregoing, l have found the relationships between the current density (J), the slip (S), the dielectric constant of the gas-particle mixture (K), and the theoretical cluster radius (R) to be generally the same for a wide range of geometric variables and efficiencies.

For example, concentric cylinder structure with outer and inner cylinders of 8 inches and 3 inches, 2 inches and seven-eighths inch, and three-fourths inch and one-fourth inch, respectively, all exhibited the fol- 1O lowing trends:

S amps/cm R The use of a non-conductive filter body of sintered glass particles to trap impurities in an electrostatic,

it suitable for my purposes. More specifically, to be an effective collector or trap for the particles propelled to a collecting electrode in the type of device I have invented, the material must not only be non-conducting,

These values were exhibited over a wide range of efficiency values and electric field intensities. The results point toward the fact that modest increases in R caused cies of the present novel process.

It is within the compass of my invention to collect the particles to be separated on a bare conductor or electrode disposed in the highest intensity region of the non-uniform field. However, the particles will in many cases tend to scatter from a bare electrode because a charge can be imparted to them as they migrate to and impinge on the electrode. The charged particles are then repelled from the electrode and scattered. Accordingly, for many applications, I prefer to surface the portion of the collecting electrode to which the particles migrate with a nonconductive material as it has been found that this materially increases the particle retaining capability of the collecting electrode or conductor.

but it must have a dielectric constant close to that of the gas in which the particles being separated are dis persed as the latter exists under the influence of the nmwfiormfiefiff is ,7 r

This readily distinguishes my invention from devices such as those disclosed in the above-cited Japanese Pat. Publication No. 293153 in which the collecting electrode is surrounded by a material having a EsLhLshstisLssls savsentsash as l e Also, a high degree of porosity is a characteristic of some useful materials. However, this is not essential is the material otherwise has surface or other adhesive characteristics which make it capable of retaining particles propelled against it.

Several materials have proven to be satisfactory for the purposes discussed above. These are porous ceramics, epoxy and urethane foams, fiberglass, glass cloth, coatings of alumina and other materials, and oil coatings.

A number of tests were run in which the inner electrode of a device as shown in FIG. 2 was coated with various materials. The results are summarized below:

TABLE IV Cross-Sectional Area of Flow Passage Between Inner & Outer Inner Conductors (b ,a Electrode Relative in Square Inches Cover Efficiency POLLUTANT: Talc Greater Than Square Inches None (Bare Electrode) 0.92

I V n W r l 5 lot 1.00

POLLUTANT: A.C. Fine Test Dust None (Bare Electrode) 0.80

From 75 sguare Fiberglass Cloth 1.00

no es to POLLUTANT: Dl-2 Ethylhexy 10 Square Inches Phthalate (DOP) None (Bare Electrode) 0.86

Fiberglass 0.89

Polyurethane Foam (97% Voids) 0.97

n Polyurethane Foam & Swirler (97% Voids) L00 POLLUTANT: A.C. Fine Test Dust Less Than l0 Square Inches None (Bare Electrode) 0.92

T 'w Epoxv Foam w'th S c Fi I 1.00

POLLUTANT: Dl-2 Ethylhexyl Phthalate (DOP) Less Than l0 Square Inches None (Bare Electrode) 0.73

13 TABLE IVLCOFGEET crosssectional Area of Flow Passage l. A.C. Fine Test Dust is a commercially available dust supplied by the AC Spark Plug Division of the General Motors Corporation. The particle size distribution is:

to microns 39 i- 2% 5 to ID microns 18 i 3% l0 to microns l6 3% 20 to 40 microns l8 1 3% 40 to 80 microns 9 i 3% 2, The swirler used in this series of tests was constructed from galvanized sheet metal in the form of stationary vanes and was used to deflect and rotate the gas stream and thereby create turbulence to make the separation process more efficient.

It will be apparent from the foregoing that significantly superior results were in each instance obtained by using a collector material having the characteristics described above. In contrast, materials such as Teflon, which is non-conducting and has a low dielectric constant, has been found not to be satisfactory as a collector material because it is not capable of retaining the particles impinging on it.

The tests in which the foregoing data were generated were conducted essentially in the manner hereinafter described in conjunction with Examples I-VI.

In conjunction with the foregoing, the advantages of employing a coating of non-conducting material having a low dielectric constant can in certain applications be obtained by employing a layer of the collected particles as a coating; that is, by allowing the particles of the separated material to build up and form a film or layer on the surface of the electrode.

As indicated above, separation systems in accord with the principles of the present invention may have a variety of physical configurations. One such system 20, illustrated in FIG. 3, includes among its major components a separation unit 22,.a high voltage power supply 24, and a blower or other pump 26 for the gas from which the desired substance or substances are to be separated.

The term pump is intended to be used herein in an extremely broad sense. For example. the gases were supplied to one actual separation unit 22 as shown in FIG. 3 from a port in the stack ofa petrochemical plant, the function of the separation unit being to remove particulates from the stack gases prior to entry into an oxygen analyzer incorporated in the controlsystcm of the plant. In this application, therefore, the pumping was by the naturaldraft in the stack.

Separation unit 22 includes an elongated, outer electrode 28 in the form of a vertical cylinder. This electrode is grounded through lead 29. Flanges 30 and 31 are fixed to the ends of electrode 28 as by welding.

The interior of outer electrode 28 is converted into a closed chamber by an end plate 32 and an insulator 33. Endplate 32 is fixed to flange 30 as by fasteners 34. An O-ring 35 keeps gases in electrode 28 from leaking between flange 30 and end plate 32 to the exterior of separation unit 22 fig Insulator 33 is similarly fixed to the flange 31 at the opposite of the end of the separation unit as by fasteners 36 with an O-ring 38 being employed to prevent leakage at this end of the separation unit.

A second, circularly sectioned, elongated, inner electrode 40 is supported concentrically within outer electrode 28 by insulator 33. The insulator has a recess 42 in which one end of electrode 40 is secured. As shown in FIG. 3, inner electrode 40 has a rounded end 43. This is to prevent corona discharge from the electrode.

In this embodiment of the invention, a non-uniform field is established between inner and outer electrodes 40 and 28 by energizing the inner electrode from power supply 24. The field lines converge on inner electrode 40. Accordingly, the inner electrode is preferably surrounded by a layer of filter material 44 to collect particles propelled to it by the non-uniform field as discussed above.

The gas from which particles are to be separated enters separation unit 22 through an inlet 46 in a fitting 48, flows through the annular passage 50 between the inner and outer electrodes, and is discharged from the unit through a passage 52 in outlet fitting 54.

Referring still to FIG. 3, power supply 24 may be of any conventional construction. The power supply is connected to inner electrode 40 by lead 56, which extends through aperture 58 in insulator 33 to an attachment plug 60. This plug is, in turn, connected to inner electrode 40.

In this and other embodiments of the invention, the outer conductor can be connected to the power supply and the inner conductor grounded, if desired. However, the arrangement just described is preferred for safety reasons.

The remaining component of the system shown in FIG. 3; via., circulator 26, may be a blower or other gas pump. Or, as indicated above, the gas from which particles are to be separated may emanate from a source such as a stack, the exhaust system of an internal or external combustion engine, etc. Furthermore, it will be obvious to those knowledgeable in the relevant arts that the circulator can be employed on the exhaust rather than the supply side of unit 22 or that 'circulators can be used on both the supply and exhaust sides of the separation unit, if desired.

As indicated above, in the operation of system 20, high voltage power supply 24 is energized, establishing a high intensity, non-uniform electrical field between inner electrode 40 and outer electrode 28 of separation unit 22. Circulator 26 is then started, effecting a flow of the gas from which particles are to be separated through the annular passage 50 between electrodes 28 and 40 in the direction shown by arrows 64 in FIG. 3. As the gas flows through passage 50, the force resulting from the non-uniform field between the electrodes deflects the particles mixed with the gas along with the gas itself toward the region of the field Where the field strength is highest, which is adjacent inner conductor 40. Here the particles are trapped by filter 44.

There are a number of critical factors and interrelationships between these factors which must be observed to make a separation unit 22 as just described operable. 

2. A method of separating particles of solid and liquid substances from air and other gases, comprising the steps of: a. establishing a non-uniform electrical field between first and second electrode means, at least one of which has one or more flow passages therethrough, said field being established by impressing across said electrode means a voltage which is such that the maximum value of the non-uniform electrical field is below the breakdown strength of the gas from which flow particles are to be separated; b. effecting a flow of the gas in which the particles to be separated are dispersed through said one electrode means to the other of the electrode means to thereby cause said gas and the particles to be separated therefrom to traverse and interact with the non-uniform electrical field, whereby the force created by said field will move said particles to the region of the non-uniform field in which the field intensity is highest; c. polarizing the gas in which the particles to be separated are dispersed so that said gas will move with said particles to the region of the field in which the particles are to be collected to thereby reduce to a minimum the drag forces on the particles and increase the efficiency of the separation process; and d. collecting in the region of the field in which the field intensity is the highest particles moving thereto with the gas in which they are dispersed under the influence of the nonuniform field.
 3. A method of separating particles of solid and liquid substances from air and other gases flowing through a conduit means having an electrically conductive inner surface, comprising tHe steps of: a. disposing an electrode means in said conduit means; b. establishing a non-uniform field between said electrode means and said conduit means, said non-uniform field being established by impressing across said electrode means and said conduit means a voltage which is such that the maximum value of the non-uniform field is below the breakdown strength of the gas from which flow particles are to be separated; c. effecting a flow of the gas in which the particles to be separated are dispersed through said conduit means to thereby cause said gas and the particles to be separated therefrom to traverse and interact with the non-uniform electrical field, whereby the force created by said field will move said particles to the region of the non-uniform field in which the field intensity is highest; d. polarizing the gas in which the particles to be separated are dispersed so that said gas will move with said particles to the region of the field in which the particles are to be collected to thereby reduce to a minimum the drag forces on the particles attributable to the motion of the particles in the gas and increase the efficiency of the separation process; and e. collecting in the region of the field in which the field intensity is the highest particles moving thereto with the gas in which they are dispersed under the influence of the non-uniform field.
 4. The method of claim 3, wherein the inner surface of the conduit means is made electrically conductive by disposing a coating of an electrically conductive material thereon.
 5. A method of separating particles of solid and liquid substances from air and other gases, which comprises the steps of: a. establishing a non-uniform electrical field between first and second electrically isolated electrode means by impressing across said electrode means a voltage which is such that the maximum value of the non-uniform electrical field is below the breakdown strength of the gas from which flow particles are to be separated; b. effecting a flow of the gas in which the particles to be separated are dispersed through a passage between said first and second electrode means to thereby cause said gas and the particles to be separated therefrom to traverse and interact with the non-uniform electrical field, whereby the force created by said field will move said particles to the region of the non-uniform field in which the field intensity is highest; c. creating and maintaining a current between said first and second electrode means such that the maximum current density in the non-uniform field is not more than 10 6 amperes per square centimeter to thereby reduce to a minimum the drag forces on the particles attributable to the movement of the particles in the gas and increase the efficiency of the separation process; and d. collecting in the region of the field in which the field intensity is the highest particles moving thereto with the gas in which they are dispersed under the influence of the non-uniform field.
 6. The method of claim 5, wherein the particles are collected at one of said electrode means and including the step of removing from said electrode means the particles collected thereat by vibrating said electrode means.
 7. The method of claim 5, wherein the particles are collected at one of said electrode means and including the step of removing from said electrode means the particles collected thereat by directing a flow of fluid against said electrode means.
 8. The method of claim 5, wherein the particles are collected at one of said electrode means and including the step of removing from said electrode means the particles collected thereat by vacuuming the collected particles from the electrode means.
 9. The method of claim 5, wherein the particles are collected at one of said electrode means and including the step of removing from said electrode means the particles collected thereat by moving a means having cleaning elements engageable wIth said electrode means relative thereto.
 10. The method of claim 5, wherein the particles are collected at one of said electrode means and including the step of removing from said electrode means the particles there collected by flexing the portion of the electrode means on which said particles are separated to thereby free the collected particles from said electrode.
 11. The method of claim 5, wherein the electrode means have curved surface portions and wherein the voltage impressed across the electrode means is maintained at a level where grad E 2 < or = 4 E2 max 1/a, where grad E 2 is the gradient of the field squared, Emax is the breakdown field strength of the gas in which the particles are dispersed, and 1/a is the maximum curvature of any equipotential line in the non-uniform field.
 12. The method of claim 5, wherein at least one of the electrode means has a flat surface portion and wherein the voltage impressed across the electrode means is maintained at a level where grad E 2 < or = 2 E max 1/a, where grad E 2 is the gradient of the field squared, Emax is the breakdown field strength of the gas in which the particles are dispersed, and 1/a is the maximum curvature of any field line in the non-uniform field. 